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Diagnostic Procedures

WARNING: This page is about a different car, the 2003 Mazda MPV and 2002 Mazda MPV. However, it is still accessible from the selected car via links, so may be relevant.
  1. Record freeze frame data. Check for service bulletins and on-line information. Repair as necessary. After repair, go to next step.
  2. Verify Current Input Signal Status - Is Concern Intermittent Or Constant -  Disconnect PCM 104-pin harness connector. Connect 104-pin Breakout Box (49-UN01-130) to PCM harness connector only. See Figure. Turn ignition on, engine off. Measure voltage at breakout box terminal No. 63. If voltage reading is less than 0.1 volt, go to next step. If voltage reading is not as specified, problem is intermittent. See INTERMITTENTS in TROUBLE SHOOTING - NO CODES article.
  3. Inspect For Bent Terminal -  Turn ignition off. Disconnect fuel gauge sender unit 4-pin harness connector. Check for damaged, loose or corroded terminals. If no problem is found, go to next step. If problem is present, repair suspected terminal or connector as necessary. After repair, go to step  7.
  4. Classify Fuel Gauge Sender Unit Or Harness Malfunction -  Disconnect fuel gauge sender unit 4-pin harness connector. Turn ignition on, engine off. Measure voltage at breakout box terminal No. 63. If voltage is more than 4.9 volts, repair or replace fuel gauge sender unit as necessary. After repair, go to step  7. If voltage reading is not as specified, go to next step.
  5. Inspect Fuel Level Signal Circuit For Short To Ground -  Turn ignition off. Disconnect PCM 104-pin harness connector. Check continuity between ground and fuel gauge sending unit 4-pin harness connector terminal "A" (Gray/Red wire). See Fig 1. See appropriate wiring diagram under ENGINE PERFORMANCE in WIRING DIAGRAMS. If continuity is not present, go to next step. If continuity is present, repair short in Gray/Red wire between fuel gauge sender unit 4-pin harness connector terminal "A" and PCM 104-pin harness connector terminal No. 63. See Figure. Go to step  7.
    Fig 1: Identifying Fuel Gauge Sender Unit 4-Pin Harness Connector Terminals
    G00143780Courtesy of MAZDA MOTORS CORP.
  6. Inspect Fuel Gauge Sender Unit Circuits For Shorts -  Check continuity between fuel gauge sender unit 4-pin harness connector terminals "A" (Gray/Red wire) and "C" (Black/Orange wire). If continuity is not present, go to next step. If continuity is present, repair short in suspect wire between fuel gauge sender unit 4-pin harness connector and PCM 104-pin harness connector. After repair, go to next step.
  7. Verify Trouble Shooting Of DTC P0462 Completed -  Reconnect all disconnected connectors. Turn ignition on, engine off. Using scan tool, clear DTC. See CLEARING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. Recheck DTCs. If DTC P0462 is present, replace PCM. After repair, go to next step. If DTC P0462 is not present, go to next step.
  8. Verify After Repair Procedure -  Using scan tool, perform After Repair Procedure. See AFTER REPAIR PROCEDURE . If no other DTCs are present, testing is complete. If any other DTC is present, go to applicable test and repair.
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